Flex-O-Line: One line, many possibilities

The most impressive feature of our Flex-O-Line is its ability to switch over extremely quickly toa wide variety of formats. Thanks to the use of servo technology, many functions can be conveniently adjusted via the intuitive HMI without having to replace any mechanical components. Recipe management enables the secure storage and immediate retrieval of the optimal settings for various products and product variants. This allows not only different formats but also different product properties—such as flow behavior or foaming—to be taken into account. The integration of a filling and capping machine from a single source into a single line also enables centralized control of the entire system via a single display.

Depending on the stability of the packaging, products can be conveyed within and between the systems via a puck transport system or directly on a conveyor belt. This means that only a few, quickly interchangeable format parts are required. In addition, the line’s components can be supplemented with various modules —for example, to attach and crimp dispensers or to apply caps or overcaps.

Different industries have different requirements, but the versatility of our Flex-O-Line always comes in handy:

• In the pharmaceutical industry, small batches of various product formats—such as disinfectant sprays, nasal sprays, eye drops, or cough syrups—can be filled on the same line. This allows smaller, niche markets to be served collectively in a space-saving manner. Control via the same terminal enables a consistent flow of information for quality assurance, while the modular design allows for the integration of additional components, such as checkweighers.
• In the cosmetics industry, many different shapes can be used; for example, in combination with our puck system, a wide range of bottles can be employed to stand out at the point of sale and appeal to a variety of target audiences.
• When filling chemical and technical products, it is easy to accommodate different package sizes and the use of additional components, such as pump inserts.
• The food industry also benefits greatly from the short cleaning times required when filling different product variations.

Our Flex-O-Line is always made up of proven individual components. To achieve a high degree of flexibility and to allow for the integration of additional components at the various interfaces over time, if necessary, the “filling” and “sealing” functions have been deliberately separated.

Due to its compact design, a linear filler is ideal for filling—in particular, our AL101. The AL101 itself is highly flexible: Depending on the desired output, four, six, or eight filling stations can be integrated; if desired, only a portion of the filling stations can be fully installed initially, with the remaining stations added later as needed. This allows for filling volumes between 5 and 1,000 ml and speeds of up to 64 containers per minute. Depending on the application, the filling stations can be operated by different pump systems.

A variant of our GSM500 handles the capping process. The torque-controlled, servo-driven capping module can be individually adapted to a wide range of containers. In addition, it is possible to integrate various stations for crimping or for attaching dispensers, caps, dropper inserts, and much more.

To further increase flexibility, we—as a long-standing specialist in tube filling and capping machines—have developed a tube capping machine for plastic and aluminum tubes that handles pucks and can be easily slid onto the line. This is because tubes are increasingly part of the mix of packaging options in which a product is offered. And although the variety of tube shapes is more limited compared to bottles, new design possibilities are constantly emerging—from oval tubes and long-neck tubes to special folded blanks.